9U-7840 Fuel Injection Equipment Calibration Fluid Test Kit{0374, 0599, 0706} Caterpillar

Caterpillar Products: All

Introduction

Important Safety Information

Illustration 1	g02139237
Think Safety

European Union Compliant, CE Marked

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER","WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

Safety Section

The Safety section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.

Maintenance Section

The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal

Service Parts Section

The Service Parts section is a reference for parts identification and available part numbers.

Additional Contact Information

For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:

USA: 800-542-8665, Option 1

International: 1-309-578-7372

Note: Continuing improvement and advancement of product design can mean some photographs or illustrations in this publication will show details that are different from your service tool.

General Information Section

The quality and condition of the test fluid in fuel injection system test equipment will affect test results. Industry standards of J967D test fluid are tightly controlled for this reason. Checking fluid cleanliness, viscosity and specific gravity are essential for accurate fuel system testing. The simplest way to verify that test fluid is within J967D specifications is to monitor viscosity and specific gravity (density) on a regular basis. Filters should be replaced on a regular basis to ensure fluid quality.

Controlling viscosity is critical because internal leakage in pumps or nozzles will cause changes in delivery if the fluid is out of specification. In time the fluid will become diluted with diesel fuel and lube oil.

The 9U-7841 Viscosity Cup is calibrated to measure the viscosity of J967D Calibration Fluid between the temperatures of 16° ± 67°C (60° ± 120°F). Testing may be done on the fluid in the test stand reservoir before start up, when the fluid is at room temperature; or on a beaker of fluid left standing at room temperature for a minimum of one hour. A constant thermometer reading is an indicator to proceed with the test.

Specific gravity is also an indicator of dilution.

Many factors affect the maintenance intervals. These include testing of used injection pumps, heat, or oil dilution. Other conditions that will require the replacement of the test fluid include visible contamination, color change, and increased foaming tendency.

Maintaining a constant fluid temperature during the test is critical.

9U-7840 Diesel Fuel and Fuel Injection Equipment Calibration Fluid Test Kit

Illustration 2	g02444856

1. 4C3975 Case, Plastic

2. 9U7838 Block, Foam

3. 1 P7438 Beaker

4. 5P2712 Hydrometer, 3.8° C (39° F) 39° - 51° API

5. 1 P7408 Hydrometer, 29° - 41° API

6. 9U7839 Stopwatch

7. 9U7841 Cup, Viscosity

8. 9U7842 Beaker

9. Form NEHS0607 Not shown: Decal NEEG2600

Calibration Fluid Tests

Measuring SAE J967 Calibration Fluid Viscosity at Room Temperature Using the 9U-7842 Beaker

Note: Before testing, wipe all instruments clean of any residue (packing foam, lint, etc.) that could restrict the cup orifice. Blowout the cup orifice with compressed air if required.

Note: Make and use copies of the Maintenance Record and Data Sheet contained in this book for your records.

Note: The charts included with this booklet are calibrated for a specific cup. The serial number of your cup must match that noted on your charts for proper test results. The charts in this booklet are for reference only.

1. Draw a sample of fluid in the 9U-7842 Beaker (600 mL).

2. Slowly submerge the 9U-7841 Cup into the fluid sample. The cup portion should be completely submerged. Place one of the hydrometers in the fluid sample next to the cup. This will be used as a thermometer only. Let these soak for at least 10 minutes so all pieces stabilize at the same temperature.

3. When all temperatures have stabilized, remove the hydrometer and record the temperature.

4. Holding the stop watch in one hand and the top of the handle in the other, raise the cup completely out of the fluid in a smooth rapid vertical motion. Keep the cup as level as possible.

   Start the stop watch as soon as the top of the cup breaks the surface of the fluid. Hold the cup very steady for the first 10 seconds until the fluid level drops below the cup lip.

   Stop the watch as soon as the last drop of fluid completely drains through the hole on the inside of the cup.

5. Record the temperature and elapsed time in seconds.

6. Repeat steps 4 and 5 three times averaging the readings which should fall within one second of each other. Record the average elapsed time in seconds with temperature.

7. Locate on the vertical axis of Chart I the average elapsed time obtained from step 6. Follow the value to the diagonal line. From this point drop down vertically to read the viscosity in Centistokes {mm2/sec}. Record this viscosity.

8. Locate the viscosity on the vertical axis of Chart II. Locate the measured temperature of the test fluid on the horizontal axis. If the point of intersection of these two values is between the upper and lower limit lines the fluid is satisfactory for continued use.

Measuring SAE J967 Calibration Fluid Viscosity at Elevated Temperatures or at the Sump

The fluid can be tested at the sump if desired. All required test equipment must be submerged in the sump until all temperatures are stabilized.

Measuring API Specific Gravity of SAE J967DCalibration Fluid

Illustration 3	g02444876

Fill a 1P-7438 Beaker (1) about two-thirds full of the calibration fluid to be tested. Carefully lower the thermo-hydrometer (2) into the fluid. Push the thermo-hydrometer to below its float level, then allow it to float freely. Wait two or three minutes until the thermo-hydrometer is stationary so there are no air bubbles in the fluid, and the thermometer reading stabilizes.

Read the measured API gravity directly from the thermo-hydrometer. Use the scale on the narrow upper portion (A). To read the hydrometer scale, look at the fuel surface from slightly below the surface as shown in the left illustration. Then raise the eye slowly until this surface, which is first seen as an ellipse, becomes a straight line as shown in the right illustration. Read the API gravity number at the point this line cuts the hydrometer scale.

Record the observed API gravity. Record fluid temperature in degrees F, from the lower portion (B) of the thermo-hydrometer.

Note: If the fluid is not clear, read from above the surface and estimate as accurately as possible the point to which the fuel rises on the hydrometer scale.

Locate the intersection of the measured temperature and the measured specific gravity on Chart III. If the intersection is within the upper and lower limit, the fluid is okay. If the fluid is outside the limits it should be discarded.

Efflux Time to Viscosity Sample Chart

Illustration 4	g02444881

Viscosity Limit Chart for SAE J967Calibration Fluid

Illustration 5	g02444882

API Gravity Limit Chart for SAE J967 Calibration Fluid

Illustration 6	g02444883

Test Stand Inspection Record

Test Stand No. ______

Year ______

Illustration 7	g02444884

Test Stand Data Sheet

Illustration 8	g02444896

Measuring Diesel Fuel API Gravity

Many complaints of lack of power from diesel engines can be traced to a light grade of diesel fuel. Power obtained from diesel fuel is determined by its BTU content, which is in direct relation to its weight per gallon. By simply measuring the API (American Petroleum Institute) gravity of the fuel, the performance of the engine can be compared with the factory horsepower ratings. The horsepower ratings of diesel engines as listed in the Caterpillar Rack Setting Information were obtained with fuel having an API gravity of 35° at 60° F. If a fuel with a high API gravity is used (lighter in pounds per gallon), the power output from the engine will be lower than listed because there is less heat value per unit volume of fuel.

Measuring API Gravity of Diesel Fuel

1P-7408 Thermo-hydrometer has a range of 29°-41° API.

5P-2712 Thermo-hydrometer has a range of 39°-51° API.

Illustration 9	g02444916

Fill a 1P-7438 Beaker (1) about two-thirds full of the diesel fuel to be tested. Carefully lower the thermo-hydrometer (2) into the fuel. Push the thermo-hydrometer to below its float level, then allow it to float freely. Wait two or three minutes until the thermohydrometer is stationary so there are no air bubbles in the fuel, and the thermometer reading stabilizes.

Read the measured API gravity directly from the thermo-hydrometer. Use the scale on the narrow upper portion (A). To read the hydrometer scale, look at the fuel surface from slightly below the surface as shown in the left illustration. Then raise the eye slowly until this surface, which is first seen as an ellipse, becomes a straight line as shown in the right illustration. Read the API gravity number at the point this line cuts the hydrometer scale.

Record the observed API gravity to the nearest full degree of API. For example, read 40.4° as 40° API. Record fuel temperature in degrees F, from the lower portion (B) of the thermo-hydrometer. Do not use the right scale of the thermometer.

Note: If the fuel is not clear, read from above the surface and estimate as accurately as possible the point to which the fuel rises on the hydrometer scale.

API Degrees - Temperature Correction Chart for Diesel Fuel

Record the corrected API gravity from this chart.

Table of Horsepower Correction Factors

Use the above chart to find the horsepower correction factor.

Calculating the Corrected Horsepower

1. Determine the rated full load horsepower from the Rack Setting Information Book.

2. Divide the rated horsepower by the horsepower correction factor for fuel density; the result is the corrected horsepower.

Example:

1674 - Truck Engine Serial No. 94B2551

Rated Horsepower: 270 Horsepower

Calculations:

Correcting for Fuel Density When Testing Engines on a Dynamometer

When engines are tested on a dynamometer which measures actual flywheel or drive train output, the observed horsepower is dependent on the fuel used. If the fuel being used is not 35° API at 60°F, then any dynamometer readings must be corrected to determine the output if 35° API fuel had been used. The same horsepower correction factor is used, but the formula is different:

Corrected Horsepower = Observed Horsepower x Horsepower Correction Factor

Example:

1674 Truck Engine, Serial No. 9482551

Rated (full load Horsepower: 270 Horsepower)

Observed (dynamometer) Horsepower: 260 Horsepower

Calculations:

1. Measured API gravity: 39.6° API at 50°F (round to 40° API)

2. Corrected API Gravity (see chart): 41° API at 60°F

3. Horsepower Correction Factor (see chart): 1.038

4. Corrected Horsepower = Observed Horsepower x Horsepower Correction Factor

   260 horsepower x 1.038 = 270 horsepower

(Although the dynamometer indicated low horsepower, if the proper fuel had been used, the engine would be operating at rated output. The factory tolerance on rated engine output is ± 3%.)

REFERENCE: For more information on dynamometer testing diesel engines, see Special Instruction Form GEG01024 .

Diesel Fuel API Gravity to IbsJU.S. gallon or kg/liter Conversion Chart

The following chart may be used to convert the fuel API gravity to Ibs./U.S. gallon or kg/liter. These weights are for reference and are to be used when evaluating engine performance. Measurement of fuel flow rates can be converted to horsepower (using full load brake specific fuel consumption, BSFC, values).

All of the above measurements taken at 16° C (60° F).